Process for the production of alcohols from biomass

ABSTRACT

Alcohols useful as fuel compositions are produced from biomass by pretreating the biomass prior to hydrolysis and fermentation. In the pretreatment, the biomass is contacted with an aqueous solution containing a dilute acid with concentration of up to 10 wt % producing a predigested stream containing an aqueous liquor that contains at least a portion of hemicelluloses and a residual biomass that contains celluloses and lignin; separating at least a portion of the aqueous liquor from the residual biomass providing an aqueous liquor stream and a pre-digested biomass stream; then contacting the pre-digested biomass stream with a cooking liquor containing at least one alkali selected from the group consisting of sodium hydroxide, sodium carbonate, sodium sulfide, potassium hydroxide, potassium carbonate, ammonium hydroxide, and mixtures thereof and water. A process that allows for higher recovery of carbohydrates and thereby increased yields is provided.

The present application claims the benefit of pending U.S. Provisional Patent Application Ser. No. 61/424,821, filed Dec. 20, 2010, the entire disclosure of which is hereby incorporated by reference.

FIELD OF THE INVENTION

This invention relates to a process for the production of alcohols from cellulosic biomass.

BACKGROUND OF THE INVENTION

The basic feedstocks for the production of first generation biofuels are often seeds, like grains such as wheat and corn, that produce starch or sugar cane and sugar beets that produce sugars that is fermented into bioethanol. However, the production of ethanol from these feedstocks suffers from the limitation that much of the farmland which is suitable for their production is already in use for food production.

Biologically produced alcohols, most commonly ethanol, and less commonly propanol and butanol, can be produced by the action of enzymes and microorganisms through the hydrolysis of starches or celluloses to glucose and subsequently fermentation of sugars. Cellulosic ethanol production uses non-food crops and does not divert food away from the food chain or inedible waste products which does not change the area of farmland in use for food products. However, production of ethanol from cellulose poses a difficult technical problem. Some of the factors for this difficulty are the physical density of lignocelluloses (like wood) that can make penetration of the biomass structure of lignocelluloses with chemicals difficult and the chemical complexity of lignocelluloses that lead to difficulty in breaking down the long chain polymeric structure of cellulose into sugars that can be fermented. Thus, it requires a great amount of processing to make the sugar monomers available to the microorganisms that are typically used to produce ethanol by fermentation.

Lignocellulose is the most abundant plant material resource and is composed mainly of cellulose, hemicelluloses and lignin. Woodchips are used in pulp and paper mills to convert wood into wood pulp by chemical or physical processes, usually Kraft process. In a Kraft process, woodchips are treated in a digester with a mixture of sodium hydroxide and sodium sulfide, known as white liquor. The woodchips are impregnated with a cooking solution that contains white liquor. White liquor is produced in the chemical recovery process.

In a continuous digester, the materials are fed at a rate which allows the pulping reaction to be complete by the time the materials exit the reactor. Typically delignification requires several hours at 155 to 175° C., typically around 170° C. Under these conditions lignin and some hemicelluloses degrade to give fragments that are soluble in the strongly basic white liquor. The solid pulp (about 50% by weight based on the dry wood chips) known as brown stock is collected and washed to produce brownstock pulp that typically contains 3 to 4% by weight lignin (Kappa #20-30) for softwood and 2 to 3% by weight lignin (Kappa #10-20) for hardwood, which is further passed through a series of bleaching steps to generate paper-quality pulp. The combined liquids known as black liquor contains extracted lignins, carbohydrates, sodium hydroxide, sodium sulfide and other inorganic salts. The black liquor is at about 15% solids and is concentrated in a multiple effect evaporator to 60% or even 75% solids and burned in the recovery boiler to recover the inorganic chemicals for reuse in the process. The combustion is carried out such that sodium sulfate, added as make-up is reduced to sodium sulfide by the organic carbon in the mixture. The molten salts from the recovery boiler are dissolved in process water known as “weak white liquor” composed of all liquors used to wash lime mud and green liquor precipitates. The resulting solution of sodium carbonate and sodium sulfide is known as “green liquor”. Green liquor contains at least 4 wt %, typically 5 wt %, of sodium carbonate concentration. Green liquor is mixed with calcium hydroxide to regenerate the white liquor used in the pulping process.

Currently there exist two broad categories of processes for the hydrolysis of cellulose. One category uses mineral acids such as sulfuric acid as discussed in U.S. Pat. No. 5,726,046, while the second category uses enzymes. The mineral acid most commonly used in mineral acid process is sulfuric acid. In general sulfuric acid hydrolysis can be categorized as either dilute acid hydrolysis or concentrated acid hydrolysis.

The dilute acid processes generally involve the use of 0.5% to 15% sulfuric acid to hydrolyze the cellulosic material. In addition, temperatures ranging from 90° C. to 600° C., and pressure up to 800 psi are necessary to affect the hydrolysis. At high temperatures, the sugars degrade to form furfural and other undesirable by-products. The resulting fermentable sugar yields are generally low, less than 50% and process equipment must be employed to physically remove furfural before further processing.

The concentrated acid processes have been somewhat more successful, producing higher yields of sugar. However, these processes typically involve the use of 60% to 90% sulfuric acid to affect hydrolysis, leading to high cost due to the cost of handling concentrated sulfuric acid and it subsequent recovery.

The additional problems faced in the acid hydrolysis processes include the production of large amounts of gypsum when the spent or used acid is neutralized. The low sugar concentrations resulting from the processes require the need for concentration before fermentation can proceed. When hydrolysis is carried out at temperatures above 150° C., compounds such as furfural are produced from the degradation of pentoses. These compounds inhibit fermentation, and some may be toxic. Furthermore, the degradation of pentose sugars results in a loss of yield.

U.S. Pat. No. 4,070,232 describes the prehydrolysis step in the presence of dilute acid solutions containing a mixture of HCl, formic and acetic acid which is pretty corrosive mixture requiring expensive process equipment. Also, the recovery of hemicelluloses is low due to short residence times (7-20 min) at low temperatures (100-130° C.).

US2008/0190013 describes use of ionic liquids to pretreat lgnocellulosic material. However, ionic liquids are generally more expensive and difficult to recover, while cleaning (building-up of heavy components) is required. Minor losses will make the process uneconomical.

SUMMARY OF THE INVENTION

Accordingly, in one embodiment of the invention, a process for producing alcohol is provided comprising:

-   -   (a) providing a biomass containing celluloses, hemicelluloses         and lignin;     -   (b) contacting said biomass at a temperature within the range         from about 130° C. to about 230° C. with an aqueous solution         comprising a dilute acid with concentration of up to 10 wt % in         an aqueous solution to biomass ratio in the range of 2 to 10         thereby producing a predigested stream comprising an aqueous         liquor comprising at least a portion of hemicelluloses and a         residual biomass comprising celluloses and lignin;     -   (c) separating at least a portion of the aqueous liquor from the         residual biomass thereby providing an aqueous liquor stream and         a pre-digested biomass stream;     -   (d) contacting said pre-digested biomass stream with a cooking         liquor comprising (i) about 0.5 to about 20 wt %, based on the         cooking liquor, of at least one alkali selected from the group         consisting of sodium hydroxide, sodium carbonate, sodium         sulfide, potassium hydroxide, potassium carbonate, ammonium         hydroxide, and mixtures thereof and (ii) water, at a cooking         liquor to biomass ratio within the range of 2 to 6, at a         temperature within the range of 60° C. to 230° C. to provide a         digested biomass stream containing digested biomass containing         cellulosic material, hemicellulosic material, and lignin, and a         chemical liquor stream containing at least one sodium compound,         potassium compound, or ammonium compound;     -   (e) washing the digested biomass stream with a water stream         thereby removing at least a portion of lignin and hemicellulosic         material and producing washed digested biomass stream;     -   (f) hydrolyzing the washed digested biomass stream by treating         the streams with an enzyme solution comprising cellulases and         optionally xylanases at a pH within the range of about 3 to         about 7 at a temperature within the range of 30° C. to 90° C. to         produce a hydrolyzate containing from about 4% to 30% by weight         of fermentable sugar;     -   (g) fermenting the hydrolyzate in the presence of a         microorganism at a temperature with the range of about 25° C. to         about 55° C. at a pH within the range of about 4 to about 6         thereby producing an alcohol stream containing at least one         alcohol having 2 to 18 carbon atoms; and     -   (h) recovering at least one of said alcohol from the alcohol         stream and producing an aqueous effluent stream.

In another embodiment, the process above further comprises providing at least a portion of the aqueous liquor stream to the hydrolyzate prior to fermenting in step (g).

Yet in another embodiment, the process above further comprises providing at least a portion of the aqueous liquor stream to the washed digested biomass stream prior to hydrolyzing in step (f).

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a block schematic diagram illustrating one embodiment of the process of producing alcohol from biomass.

FIG. 2 shows a block schematic diagram illustrating another embodiment of the process of producing alcohol from biomass.

FIG. 3 shows a block schematic diagram illustrating yet another embodiment of the process of producing alcohol from biomass

FIG. 4 shows a graph of glucose formation versus time from Examples 19 to 22.

DETAILED DESCRIPTION OF THE INVENTION

It has now been found that by improving the digestion of biomass treatment and subsequent processing of such digested product, a process with high yield production of alcohol suitable for use in fuel can be obtained. The invention process has significant benefits over other biomass pretreatments wherein the toxic components such as furfural and acetic acid are essentially eliminated for the fermentation process. Also, bulk removal of lignin allows improved mass transfer of enzymes to cellulose for conversion to fermentable sugars.

In some embodiments, the systems for performing the presently disclosed methods can be configured by repurposing the components of a pulp mill that previously used the Kraft pulping process. Such repurposing can allow for the employment of the presently disclosed methods with relatively low capital investment compared to many other proposed biomass-to-ethanol methods. Further, the control objective in a typical Kraft pulping is to cook to a target kappa number to correspond to lignin content of less than 4%. (see Handbook for Pulp & Paper Technologists, published in 2002 by Angus Wilde Publications Inc., Vancouver, B.C.). In some embodiment of the invention process, the entire predigestion-digestion process is conducted under conditions that produce lignin content of 1 to 20%, preferably about 5 to about 18% then further processed in a manner to produce alcohol. It has been found that a process can be obtained to produce sugars and alcohols in high yields from biomass containing cellulosic fibers.

The present process provides a method of producing an alcohol from a lignocellulosic biomass. In reference to FIG. 1 and FIG. 2, in one embodiment of the invention process 100A or 100B, biomass 102 is provided to a predigestion system 104 that may have one or more vessels, where the biomass is contacted with an aqueous solution to produce a predigested stream containing an aqueous liquor containing hemicelluloses and a residual biomass containing celluloses and lignin. At least a portion of the aqueous liquor is separated from the predigested streamproviding an aqueous liquor stream 108 and a predigested biomass stream 106. The predigested biomass stream 106 is contacted, in a digestion system 110 that may have one or more digester(s), with a cooking liquor (optionally via cooking liquor feed stream 154) that was optionally at least a portion recycled from the recaustisized chemical recycle stream 154, to produce a digested biomass. The chemical liquor stream 168 is separated from the digested biomass to produce a digeste biomass stream 112.

The recausticized chemical recycle stream is obtained from the chemical liquor stream 168 by concentrating the chemical liquor stream in a concentration system 166 thereby producing a concentrated chemical liquor stream 164 then burning the concentrated chemical liquor stream in a boiler system 160 thereby producing chemical recycle stream 158 and a flue gas stream 162, then converting the sodium carbonate to sodium hydroxide in the recaustisizing system 156 by contacting with lime (CaO) 152 producing the cooking liquor feed stream 154 containing sodium hydroxide.

Digested biomass 112 is obtained from the digestion system 110 by at least partially digesting the lignin and hemicelluloses in the predigested biomass. The digested biomass stream 112 is then processed through a wash system 114 that may have one or more washing steps. Optionally, water recovered from the concentration system 166 can be recycled as wash water 170 to wash system 114. The thus-washed digested biomass stream 116 is provided to the enzymatic hydrolysis system 130 as feedstock or is then optionally concentrated by mechanical dewatering system 210 (FIG. 3) thereby producing high solids digested biomass stream 212 then provided to the enzymatic hydrolysis system 130. In one preferred embodiment, at least a portion of or the entire aqueous liquor stream 108 can be provided to the enzymatic hydrolysis system 130 via hydrolysis stream 124. In the enzymatic hydrolysis system 130, digested biomass and optionally hemicelluloses from the aqueous liquor stream is hydrolyzed with an enzyme solution, whereby hydrolyzate (aqueous sugar stream) 132 is produced and fermented in the fermentation system 140 in the presence of a microorganism(s) to produce a fermented product stream containing at least one alcohol (alcohol stream 142). In another preferred embodiment, at least a portion of or the entire aqueous liquor stream 108 can be provided to the fermentation system 140 via fermentation stream 134. The alcohol 182 can then be recovered in a recovery system 180 from the alcohol stream 142 also producing aqueous effluent stream 184. Lignin can be optionally removed after the hydrolysis system, after the fermentation system or after the recovery system by lignin separation system 120, a, b, c, respectively removing lignin as a wet solid residue 128 a, b, c. In reference to FIG. 1, the aqueous effluent stream after the removal of lignin can be optionally recycled as aqueous effluent recycle stream 186 to the chemical recycle stream 158 thereby reducing fresh water intake in the overall process. Optionally, the aqueous effluent recycle stream 186 can be recycled as wash water to wash system 114. In reference to FIG. 2, the aqueous effluent stream 184 can be recycled without the lignin separation system to the chemical liquor stream 168 and recycled and processed as described above.

In reference to FIG. 3, in another embodiment of the invention process, the washed digested biomass stream 116 is optionally concentrated by mechanical dewatering system 210 thereby producing high solids digested biomass stream 212 then provided to the enzymatic hydrolysis system 130. The washed digested biomass stream 110 or the high solids digested biomass stream 212 is optionally delignified in the oxygen delignification system 220 thereby producing delignified digested biomass stream 222 then provided to the enzymatic hydrolysis system 130. In another embodiment the washed digested biomass stream 110, the high solids digested biomass stream 212 or the delignified digested biomass stream 222 is optionally mechanically refined in the mechanical refining system 230 thereby producing a refined digested biomass stream 232 then provided to the enzymatic hydrolysis system 130. Any of 210, 220 or 230 system maybe optionally used in any combination of one, two or three process combinations.

The Figures are included as an example of how the present invention can be practiced and is not meant to be limiting in any manner.

Any suitable (e.g., inexpensive and/or readily available) type of biomass can be used. Suitable lignocellulosic biomass can be, for example, selected from, but not limited to, forestry residues, agricultural residues, herbaceous material, municipal solid wastes, waste and recycled paper, pulp and paper mill residues, and combinations thereof. Thus, in some embodiments, the biomass can comprise, for example, corn stover, straw, bagasse, miscanthus, sorghum residue, switch grass, bamboo, water hyacinth, hardwood, hardwood chips, hardwood pulp, softwood, softwood chips, softwood pulp, and/or combination of these feedstocks. The biomass can be chosen based upon a consideration such as, but not limited to, cellulose and/or hemicelluloses content, lignin content, growing time/season, growing location/transportation cost, growing costs, harvesting costs and the like.

Prior to pretreatment with the aqueous solution, the biomass can be washed and/or reduced in size (e.g., chopping, crushing or debarking) to a convenient size and certain quality that aids in moving the biomass or mixing and impregnating the chemicals from cooking liquor. Thus, in some embodiments, providing biomass can comprise harvesting a lignocelluloses-containing plant such as, for example, a hardwood or softwood tree. The tree can be subjected to debarking, chopping to wood chips of desirable thickness, and washing to remove any residual soil, dirt and the like.

In the predigestion system, the biomass is contacted with an aqueous solution containing a dilute acid with concentration of up to 10 wt %, more preferably up to 2 wt %, even more preferably from 0.2-1 wt %. The time and temperature of contact is such that effectively produces a predigested stream containing an aqueous liquor containing hemicelluloses and a biomass containing celluloses and lignin. The contents can be kept at a temperature within the range of from 130° C. to 230° C. for a period of time, more preferably within the range from about 140° C. to about 170° C. The aqueous solution to biomass ratio can be within the range of 2 to 8, preferably 3 to 5. At least a portion of the of the aqueous liquor is separated from the predigested stream providing an aqueous liquor stream containing hemicelluloses and a pre-digested biomass stream containing celluloses and lignin. Some lignin or cellulose may be present in the aqueous liquor stream and some hemicelluloses may be remaining in the predigested biomass stream. In an embodiment, the aqueous liquor stream can be recycled to concentrate the hemi-celluloses to higher than 10 wt %, preferably even higher than 15 wt % before further processing In an embodiment the residual organic acid left with pre-digested biomass gets neutralized with the base addition in the subsequent digestion step and eventually get burned in the recovery boiler.

The dilute acid may include, for example, weak organic acids such as formic, acetic, citric, levulinic, and other similar acids with concentrations in the range of from 0.01 wt %, to 10 wt %, preferably from 0.05 to 2 wt %.

In the digestion system, the predigested biomass is contacted with the cooking liquor in at least one digester where the pretreatment reaction takes place. In one aspect of the embodiment, the cooking liquor contains (i) at least 0.5 wt %, more preferably at least 4 wt %, to 20 wt %, more preferably to 10 wt %, based on the cooking liquor, of at least one alkali selected from the group consisting of sodium hydroxide, sodium carbonate, sodium sulfide, potassium hydroxide, potassium carbonate, ammonium hydroxide, and mixtures thereof, (ii) optionally, 0 to 3%, based on the cooking liquor, of anthraquinone, sodium borate and/or polysulfides; and (iii) water (as remainder of the cooking liquor). In some embodiments, the cooking liquor may have an active alkali of between 5 to 25%, more preferably between 10 to 20%. The term “active alkali”(AA), as used herein, is a percentage of alkali compounds combined, expressed as sodium oxide based on weight of the biomass less water content (dry solid biomass). If sodium sulfide is present in the cooking liquor, the sulfidity can range from about 15% to about 40%, preferably from about 20 to about 30%. The term “sulfidity”, as used herein, is a percentage ratio of Na₂S, expressed as Na₂O, to active alkali. The cooking liquor to biomass ratio can be within the range of 2 to 6, preferably 3 to 5. The digestion reaction is carried out at a temperature within the range of 60° C. to 230° C., and a residence time within 0.25 h to 4 h. The reaction is carried out under conditions effective to provide a digested biomass stream containing digested biomass having a lignin content of 1% to 20% by weight, based on the digested biomass, and a chemical liquor stream containing sodium compounds and dissolved lignin and hemicelluloses material.

The predigester and digester can be, for example, a pressure vessel of carbon steel or stainless steel or similar alloy. The predigestion system and digestion system can be carried out in the same vessel or in a separate vessel. The cooking can be done in continuous or batch mode. Suitable pressure vessels include, but are not limited to the “PANDIA™ Digester” (Voest-Alpine Industrienlagenbau GmbH, Linz, Austria), the “DEFIBRATOR Digester” (Sunds Defibrator AB Corporation, Stockholm, Sweden), M&D (Messing & Durkee) digester (Bauer Brothers Company, Springfield, Ohio, USA) and the KAMYR Digester (Andritz Inc., Glens Falls, N.Y., USA).

The cooking liquor has a pH from 8 to 14, preferably around 10 to 13 depending on alkali used. The pH of the system may be adjusted from acidic to the pH of the cooking liquor prior to entry of the digestion system, however, it is not necessary to do so and the predigested biomass stream may be directly contacted with the cooking liquor. The contents can be kept at a temperature within the range of from 60° C. to 230° C., preferably from 100° C. to 230° C., for a period of time, more preferably within the range from about 130° C. to about 180° C. The period of time can be from about 0.25 to 4.0 hours, preferably from about 0.5 to about 2 hours, after which the pretreated contents of the digester are discharged. For adequate penetration, a sufficient volume of liquor is required to ensure that all the chip surfaces are wetted. Sufficient liquor is supplied to provide the specified cooking liquor to biomass ratio. The effect of greater dilution is to decrease the concentration of active chemical and thereby reduce the reaction rate.

The invention process has significant benefits over other acidic pretreatments wherein the toxic components such as furfural and acetic acid are essentially eliminated for the fermentation system. Also, bulk removal of lignin allows improved mass transfer of enzymes to cellulose for conversion to fermentable sugars and lower equipment and energy requirements due to smaller volumes going forward. In an embodiment of the process allows for higher recovery of carbohydrates and thereby increased yields. In another embodiment of the process allows additional flexibility to treat a hemicelluloses rich stream to be converted to a fuel or chemical via different processing route more amenable to the chemical composition of this stream. For example, the five-carbon sugars present in the hemicelluloses rich stream can easily be converted to furanic fuels via dehydration in high yields without fermentation that requires long residence times and hence high capital investments. In another embodiment pre-digestion of the hemicelluloses allows to reduce the load on the recovery boiler in the pulp mill, thereby allowing to process increased capacity of feed and hence more fuel.

In some embodiments, the pretreatment could further comprise the use of one or more additives to increase the yield of carbohydrates. Such additives include, but are not limited to, anthraquinone, sodium borate and sodium polysufides and combinations thereof.

In the wash system, the digested biomass stream can be washed to remove one or more of non-cellulosic material, non-fibrous cellulosic material, and non-degradable cellulosic material prior to enzymatic hydrolysis. The digested biomasss stream is washed with water stream under conditions to remove at least a portion of lignin and hemicellulosic material in the digested biomass stream and producing washed digested biomass stream having solids content of 5% to 15% by weight, based on the washed digested biomass stream. For example, the digested biomass stream can be washed with water to remove dissolved substances, including degraded, but non-fermentable cellulose compounds, solubilised lignin, and/or any remaining alkaline chemicals such as sodium compounds that were used for cooking or produced during the cooking (or pretreatment). The washed digested biomass stream may contain higher solids content by further processing such as mechanical dewatering as described below.

In a preferred embodiment, the digested biomass stream is washed counter-currently. The wash can be at least partially carried out within the digester and/or externally with separate washers. In one embodiment of the invention process, the wash system contains more than one wash steps, for example, first washing, second washing, third washing, etc. that produces washed digested biomass stream from first washing, washed digested biomass stream from second washing, etc. operated in a counter current flow with the water, that is then sent to subsequent processes as washed digested biomass stream. The water is recycled through first recycled wash stream and second recycled wash stream and then to third recycled wash stream Water recovered from the chemical liquor stream by the concentration system can be recycled as wash water to wash system. It can be appreciated that the washed steps can be conducted with any number of steps to obtain the desired washed digested biomass stream. Additionally, in one embodiment the washing step adjusts the pH for subsequent hydrolysis step where the pH is about 5. In another embodiment the pH of the pulp can be adjust using the CO₂ released from sugars fermentation.

In some embodiments, the materials or chemicals can be regenerated thereby reducing the addition of fresh make-up chemical cost and lowering the load on the effluent plant. The recovery of chemicals and energy from the residual chemical liquor stream are integral part of the process. In one embodiment, a weak chemical liquor stream (about 15% solids), that can be obtained from the digested biomass wash system, from the digestive system, and optionally from a oxygen delignification unit, is concentrated through a series of evaporation and chemical addition steps into a heavy or concentrated chemical liquor at about 60-75% solids. Subsequently, the concentrated chemical liquor stream is incinerated (or burned) in the recovery furnace to form inorganic smelt. The lignin and the solubilised sugar components can be used as an energy source in this combustion step. In some embodiments, lignin collected following an enzymatic hydrolysis step can be optionally added to the concentrated chemical stream to increase the lignin content. In some embodiments, the lignin can be used as energy source to provide heat during the distillation of alcohol or any other step in the biomass-to-alcohol process. In some embodiments, the lignin can be co-fired as fuel for the lime-kiln in the recausticizing operation or in a power boiler for steam and power generation. The smelt from the furnace can be dissolved by addition of water or any recycle aqueous stream (for example, the aqueous effluent stream from bottoms of the distillation). The chemicals are then subjected to recausticizing operation where the chemicals are regenerated using burned lime to form the cooking liquor.

Optionally, the pretreated and washed biomass can be refined using any suitable mechanical refining device to further break down the material in size prior to enzymatic hydrolysis. For example, the contents of the pretreatment pressure vessel can be discharged into a mechanical disc refiner or PFI refiner (or other typical refiner used in the pulping industry) to break the cooked biomass open and reduce the cooked biomass to fibers that have improved enzymatic digestibility. In some embodiments, the refining can provide bundles of cellulose fibers, single cellulose fibers, fragments of cellulose fibers, or combinations thereof. In some embodiments, refining provides largely single fibers and bundles of single fibers. In some embodiments, refining can provide pretreated biomass wherein over 90% of the material is single fibers or fragments of single fibers.

Generally, not all the lignin is removed by the pretreatment reaction. In some embodiments, at least a portion of the residual lignin can be removed from the washed digested biomass stream by oxygen delignification. Accordingly, in some embodiments, solids from the pretreated lignocellulosic mixture can be collected (via filtration or decanting of any liquids), dried and placed in an aqueous alkaline solution (e.g., water comprising 2% to 5% by weight of NaOH). The alkaline solution of solids can then be placed in a pressurized vessel and treated with oxygen gas at an elevated temperature, such as between about 60° C. and about 150° C., for a period of time effective to remove at least a portion of the lignin, such as between about 10 minutes to about 4 hours. In some embodiments, the lignin can then be removed via washing (e.g., in water). In some embodiments, oxygen delignification can be performed prior to a refining system, such that the final pretreated lignocellulosic biomass mixture (i.e., the biomass used for enzymatic hydrolysis and fermentation) is a mixture that has been treated with cooking liquor, washed, subjected to oxygen delignification, and refined. In an oxygen delignification system, a portion of the lignin is removed from one of washed digested biomass stream, hydrolyzate, or alcohol stream prior to step (d) or (e). The resulting washed digested biomass stream, hydrolyzate, or alcohol stream containing less than 5 wt % lignin content, more preferably less than 3 wt % lignin content, based on such stream.

Optionally, the washed digested biomass stream can be concentrated by mechanical dewatering to produce a high solids digested biomass stream having about 15% to 40 wt % solids. The mechanical dewatering can be carried out by any mechanical dewatering devices including, for example, filter presses, rotary washers and/or screw presses, to produce a high solids digested biomass stream having up to 40 wt % solids, more preferably up to 30 wt % solids. Higher consistency (or solids) digested biomass leads to concentrated beer stream at the back end, thereby lowing the equipment size for the hydrolysis/fermentation vessels reducing the capital cost and additionally saving on energy, e.g. 50% energy saving by distilling concentrated (10%) versus dilute beer stream (4%).

Therefore, in another embodiment, solids in the washed digested biomass stream is mechanically refined prior to contacting the washed digested biomass stream with cellulases in step (g), thereby reducing the solids in size. In another embodiment, the concentrated washed digested biomass stream is subjected to oxygen delignification prior to contacting the washed digested biomass stream with cellulases in step (j). In another embodiment, the concentrated washed digested biomass stream is subjected to mechanically refining solids in the washed digested biomass stream prior to contacting the washed digested biomass stream with cellulases in step (i), thereby reducing the solids in size. In another embodiment, the concentrated washed digested biomass stream is subjected to oxygen delignification and mechanically refining solids in the washed digested biomass stream prior to contacting the washed digested biomass stream with cellulases in step (j), thereby reducing the solids in size. In another embodiment, the washed digested biomass stream is subjected to oxygen delignification and mechanically refining solids in the washed digested biomass stream prior to contacting the washed digested biomass stream with cellulases in step (j), thereby reducing the solids in size.

In yet another embodimen, in step (i) the water stream is flowing countercurrent to the digested biomass steam.

In yet another embodiment, at least a portion of the lignin is removed from one of washed digested biomass stream, hydrolyzate, or alcohol stream prior to step (j) or (k) thereby providing a washed digested biomass stream, hydrolyzate, or alcohol stream containing less than 5% lignin content based on said stream.

In yet another embodiment, the chemical liquor stream from step (i) is concentrated to produce a concentrated chemical liquor stream, the concentrated chemical liquor stream is burned to produce a chemical recycle stream, the chemical recycle stream is recausticized to produce a cooking liquor feed stream, and the cooking feed stream is recycled to the digester in step (k) as at least a portion of the cooking liquor. In yet a further embodiment, at least a portion of the lignin is removed from the aqueous effluent stream to produce an aqueous effluent recycle stream which is recycled through the chemical recycle stream.

Optionally, following the pretreatment and/or any other desired pretreatment steps (washing, refining, oxygen delignifying, mechanical dewatering), the pretreated biomass and/or fibers can then be subjected to enzymatic hydrolysis for conversion to fermentable sugars. The enzymatic hydrolysis can be carried out at between about 5 and about 15% fiber consistency or at a higher consistency between 15 to 40%. In some embodiments, the lignocelluloses-degrading enzymes can be mixed with pretreated mixture at a fiber consistency of about 5% to about 15% for a few minutes (between 1-20 minutes), thickened using a filter press and allowed to hydrolyze for an additional period of time at the higher fiber consistency. Additional enzymes can be added to the thinned mixture. The term “fermentable sugar” refers to oligosaccharides and monosaccharides that can be used as a carbon source by a microorganism in a fermentation process.

In the enzymatic hydrolysis processes 130 the pH of the pretreated feedstock to the enzymatic hydrolysis is typically adjusted so that it is within a range which is optimal for the cellulose enzymes used. Generally, the pH of the pretreated feedstock is adjusted to within a range of about 3.0 to about 7.0, or any pH there between. For example, the pH may be within a range of about 4.0 to about 6.0, or any pH there between, more preferably between about 4.5 and about 5.5, or any pH there between, or about 3.0, 3.2, 3.4, 3.6, 3.8, 4.0, 4.2, 4.4, 4.6, 4.8, 5.0, 5.2, 5.4, 5.6, 5.8, 6.0, 6.2, 6.4, 6.6, 6.8, 7.0 or any pH there between. Since the pretreated feedstock is alkaline, an acid such as, for example, sulfuric acid or nitric acid may be used for the pH adjustment.

The temperature of the pretreated feedstock is adjusted so that it is within the optimum range for the activity of the cellulose enzymes. Generally, a temperature of about 15° C. to about 100° C., about 30° C. to about 70° C. preferably or any temperature there between, is suitable for most cellulose enzymes, for example a temperature of 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55° C., or any temperature there between. The cellulase enzymes and the β-glucosidase enzyme are added to the pretreated feedstock, prior to, during, or after the adjustment of the temperature and pH of the aqueous slurry after pretreatment. Preferably the cellulase enzymes and the β-glucosidase enzyme are added to the pretreated lignocellulosic feedstock after the adjustment of the temperature and pH of the slurry.

By the term “cellulase enzymes” or “cellulases,” it is meant a mixture of enzymes that hydrolyze cellulose. The mixture may include cellobiohydrolases (CBH), glucobiohydrolases (GBH), endoglucanases (EG), and β-glucosidase. In a non-limiting example, a cellulase mixture may include EG, CBH, and β-glucosidase enzymes. The EG enzymes primarily hydrolyzes cellulose polymer in the middle of the chain to expose individual cellulose chains. There are two types of CBH enzymes, CBHI and CBHII. CBHI and CBHII cleave the reducing and non-reducing end of the cellulose chains ends to produce cellobiose. The conversion of cellobiose to glucose is carried out by the enzyme β-glucosidase. By the term “β-glucosidase”, it is meant any enzyme that hydrolyzes the glucose dimer, cellobiose, to glucose. The activity of the β-glucosidase enzyme is defined by its activity by the Enzyme Commission as EC 3.2.1.21. The β-glucosidase enzyme may come from various sources; however, in all cases, the β-glucosidase enzyme can hydrolyze cellobiose to glucose. The β-glucosidase enzyme may be a Family 1 or Family 3 glycoside hydrolase, although other family members may be used in the practice of this invention. It is also contemplated that the β-glucosidase enzyme may be modified to include a cellulose binding domain, thereby allowing this enzyme to bind to cellulose.

The enzymatic hydrolysis may also be carried out in the presence of one or more xylanase enzymes. Examples of xylanase enzymes that may also be used for this purpose and include, for examples, xylanase 1, 2 (Xyn1 and Xyn2) and β-xylosidase, which are typically present in cellulase mixtures.

The process of the present invention can be carried out with any type of cellulase enzymes, regardless of their source. Non-limiting examples of cellulases which may be used in the practice of the invention include those obtained from fungi of the genera Aspergillus, Humicola, and Trichoderma, Myceliophthora, Chrysosporium and from bacteria of the genera Bacillus and Thermobifida. In an even more preferred aspect, the filamentous fungal host cell is an Acremonium, Aspergillus, Aureobasidium, Bjerkandera, Ceriporiopsis, Chrysosporium, Coprinus, Coriolus, Cryptococcus, Filibasidium, Fusarium, Humicola, Magnaporthe, Mucor, Myceliophthora, Neocallimastix, Neurospora, Paecilomyces, Penicillium, Phanerochaete, Phlebia, Piromyces, Pleurotus, Schizophyllum, Talaromyces, Thermoascus, Thielavia, Tolypocladium, Trametes, or Trichoderma cell.

The cellulase enzyme dosage is chosen to convert the cellulose of the pretreated feedstock to glucose. For example, an appropriate cellulase dosage can be about 0.1 to about 40.0 Filter Paper Unit(s) (FPU or IU) per gram of cellulose, or any amount there between, for example, 0.1, 0.5, 1.0, 2.0, 4.0, 6.0, 8.0, 10.0, 12.0, 14.0, 16.0, 18.0, 20.0, 22.0, 24.0, 26.0, 28.0, 30.0, 32.0, 34.0, 36.0, 38.0, 40.0 FPU (or IU) per gram of cellulose, or any amount. The term Filter Paper Unit(s) refers to the amount of enzyme required to liberate 2 mg of reducing sugar (e.g., glucose) from a 50 mg piece of Whatman No. 1 filter paper in 1 hour at 50° C. at approximately pH 4.8.

In practice, the hydrolysis is carried out in a hydrolysis system, which may include a series of hydrolysis reactors. The number of hydrolysis reactors in the system depends on the cost of the reactors, the volume of the aqueous slurry, and other factors. For a commercial-scale alcohol plant, the typical number of hydrolysis reactors may be 1 to 10, more preferably 2 to 5, or any number there between. In order to maintain the desired hydrolysis temperature, the hydrolysis reactors may be jacketed with steam, hot water, or other heat sources. Preferably, the cellulose hydrolysis is a continuous process, with continuous feeding of pretreated lignocellulosic feedstock and withdrawal of the hydrolysate slurry. However, it should be understood that batch processes are also included within the scope of the present invention. In one embodiment, a series of Continuous Stirred-Tank Reactor (CSTR) may be used for a continuous process. In another embodiment Short Contact-Time Reactor (SCTR) along with finishing reactor may be used. A thinning reactor may or may not be included in the hydrolysis system.

The enzymatic hydrolysis with cellulase enzymes produces an aqueous sugar stream (hydrolyzate) comprising glucose, unconverted cellulose and lignin. Other components that may be present in the hydrolysate slurry include the sugars xylose, arabinose, mannose and galactose, the organic acids acetic acid, glucuronic acid and galacturonic acid, as well as silica, insoluble salts and other compounds.

The hydrolysis may be carried out in two or multiple stages in a semi continuous manner (see U.S. Pat. No. 5,536,325, which is incorporated herein by reference), or may be performed in a single stage.

In the fermentation system 140, the aqueous sugar stream is then fermented by one or more than one fermentation microorganism to produce a fermentation broth comprising the alcohol fermentation product. In one embodiment, the aqueous sugar stream sent to fermentation may be substantially free of undissolved solids, such as lignin and other unhydrolyzed components so that the later step of separating the microorganism from the fermentation broth will result in the isolation of mainly microorganism; for example, lignin removal step is carried out at 120 a. The separation may be carried out by known techniques, including centrifugation, microfiltration, plate and frame filtration, crossflow filtration, pressure filtration, vacuum filtration and the like.

In the fermentation system, any one of a number of known microorganisms (for example, yeasts or bacteria) may be used to convert sugar to ethanol or other alcohol fermentation products. The microorganisms convert sugars, including, but not limited to glucose, mannose and galactose present in the clarified sugar solution to a fermentation product.

Many known microorganisms can be used in the present process to produce the desired alcohol for use in biofuels. Clostridia, Escherichia coli (E. coli) and recombinant strains of E. coli, genetically modified strain of Zymomonas mobilis such as described in U.S. Pat. Nos. 7,223,575; 7,741,119; and 7,741,084 (which disclosures are herein incorporated by reference) are some examples of such bacteria. The microorganisms may further be a yeast or a filamentous fungus of a genus Saccharomyces, Kluyveromyces, Candida, Pichia, Schizosaccharomyces, Hansenula, Kloeckera, Schwanniomyces, Yarrowia, Aspergillus, Trichoderma, Humicola, Acremonium, Fusarium, and Penicillium.

In another embodiment, for example, the fermentation may be performed with recombinant yeast engineered to ferment both hexose and pentose sugars to ethanol. Recombinant yeasts that can ferment one or both of the pentose sugars xylose and arabinose to ethanol are described in U.S. Pat. Nos. 5,789,210, 6,475,768, European Patent EP 1,727,890, European Patent EPI 863,901 and WO 2006/096130 which disclosures are herein incorporated by reference. Xylose utilization can be mediated by the xylose reductase/xylitol dehydrogenase pathway (for example, WO9742307 A1 19971113 and WO9513362 A1 19950518) or the xylose isomerase pathway (for example, WO2007028811 or WO2009109631). It is also contemplated that the fermentation organism may also produce fatty alcohols, for example, as described in WO 2008/119082 and PCT/US07/011,923 which disclosure is herein incorporated by reference. In another embodiment, the fermentation may be performed by yeast capable of fermenting predominantly C6 sugars for example by using commercially available strains such as Thermosacc and Superstart.

Preferably, the fermentation is performed at or near the temperature and pH optima of the fermentation microorganism. For example, the temperature may be from about 25° to about 55° C., or any amount there between. A typical temperature range for the fermentation of sugar to alcohol using microorganisms is between about 25° C. to about 37° C. or any temperature there between, for example from 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37° C. or any temperature there between, although the temperature may be higher if the microorganism is naturally or genetically modified to be thermostable. The pH of a typical fermentation employing microorganisms is between about 3 and about 6, or any pH there between, for example, a pH of 3.0, 3.5, 4.0, 4.5, 5.0, 5.5, 6.0, or any pH there between. The dose of the fermentation microorganism will depend on other factors, such as the activity of the fermentation microorganism, the desired fermentation time, the volume of the reactor and other parameters. It will be appreciated that these parameters may be adjusted as desired by one of skill in the art to achieve optimal fermentation conditions.

The sugar stream may also be supplemented with additional nutrients for growth of the fermentation microorganism. For example, yeast extract, specific amino acids, phosphate, nitrogen sources, salts, trace elements and vitamins may be added to the hydrolysate slurry to support growth and optimize productivity of the microorganism.

The fermentation may be conducted in batch, continuous or fed-batch modes, with or without agitation. The fermentation system may employ a series of fermentation reactors.

Preferably, the fermentation reactors are agitated lightly with mixing. In a typical commercial-scale fermentation, the fermentation may be conducted using a series of reactors, such as 1 to 6, or any number there between.

Optionally, the fermentation may be conducted so that the fermentation microorganisms are separated from the fermentation and sent back to the drawing fermentation reaction. This may involve continuously withdrawing fermentation broth from the fermentation reactor and separating the microorganism from this solution by known separation techniques to produce a microorganism slurry. Examples of suitable separation techniques include, but are not limited to, centrifugation, microfiltration, plate and frame filtration, crossflow filtration, pressure filtration, settling, vacuum filtration and the like.

In some embodiment, the hydrolysis system and fermentation system may be conducted in the same vessel. In one embodiment, the hydrolysis can be partially completed and the partially hydrolyzed stream may be fermented. In one embodiment, a simultaneous saccharification and fermentation (SSF) process where hydrolysis system may be run until the final percent solids target is met and then the hydrolyzed biomass may be transferred to a fermentation system.

The fermentation system produces an alcohol stream 142 containing at least one alcohol having 2 to 18 carbon atoms. In the recovery system 180, when the product to be recovered in the alcohol stream is a distillable alcohol, such as ethanol, the alcohol can be recovered by distillation in a manner known to separate such alcohol from an aqueous stream.

The alcohol stream (separated fermentation broth or beer) sent to the distillation is a dilute alcohol solution including unconverted cellulose and residual lignin. It may also contain components added during the fermentation to support growth of the microorganisms, as well as small amounts of microorganism that may remain after separation. The alcohol stream is preferably degassed to remove carbon dioxide and then pumped through one or more distillation columns to separate the alcohol from the other components. The column(s) in the distillation unit is preferably operated in a continuous mode, although it should be understood that batch processes are also encompassed by the present invention. Furthermore, the column(s) may be operated at greater than atmospheric pressure, at less than atmospheric pressure or at atmospheric pressure. Heat for the distillation process may be added at one or more points either by direct steam injection or indirectly via heat exchangers. The distillation unit may contain one or more points either by direct steam injection or indirectly via heat exchangers. The distillation unit may contain one or more separate beer and rectifying columns. In this case, dilute beer is sent to the beer column where it is partially concentrated. From the beer column, the vapor goes to a rectification column for further purification. Alternatively, a distillation column is employed that comprises an integral enriching or rectification section. The remaining water may be removed from the vapor by a molecular sieve resin, by adsorption, or other methods familiar to those of skill in the art. The vapor may then be condensed and denatured.

If the product to be recovered in the alcohol stream is not a distillable alcohol, such as fatty alcohols, the alcohol can be recovered by removal of alcohols as solids or as oils 182 from the fermentation vessel, thus separating from the aqueous effluent stream 184. In such an embodiment, it will be desirable to remove the lignin prior to the fermentation system as described above. In one embodiment, for example, such recovery can be carried out in a manner described in WO 2008/119082 and PCT/US07/011,923 which disclosures are herein incorporated by reference.

While the invention is susceptible to various modifications and alternative forms, specific embodiments thereof are shown by way of examples herein described in detail. It should be understood, that the detailed description thereto are not intended to limit the invention to the particular form disclosed, but on the contrary, the intention is to cover all modifications, equivalents and alternatives falling within the spirit and scope of the present invention as defined by the appended claims. The present invention will be illustrated by the following illustrative embodiment, which is provided for illustration only and is not to be construed as limiting the claimed invention in any way.

ILLUSTRATIVE EXAMPLES

General Methods and Materials

Experimental Methods

Pre-Digestion and Digestion

Wood predigestion and digestion are caned out in 500 ml zipperclave reactor (Autoclave Engineers, Inc.). Wood chips are weighed and placed in the reactor. The composition of the aqueous solution charge for pre-digestion and digestion is provided in Table 1. After the reaction is complete the aqueous liquor is separated from the treated product mixture using filter. The content of the aqueous liquor is analyzed for carbohydrate composition. The residual biomass is used for digestion. Digestion is carried in the same unit after washing and drying the substrate following pre-digestion step. Additionally, digestion step can be carried out in multi-throughput reactor using Parr 5000 unit (Parr Instruments, Inc.). The unit contained six 75 ml batch units that can be run in parallel using the same pre-digested substrate (Table 1, example 5-8). Compositional analysis of the residual biomass is carried out to determine the carbohydrate and lignin content.

Enzymatic Hydrolysis

All the predigested/digested biomass samples from digestion were hydrolyzed using a mixture of Cellulases GC220 obtained from Genencor. The reaction were conducted in 10 ml stirred glass reactor at 50° C. The digested biomass samples are loaded in the reactor with the solid on a 2 wt % glucan basis as indicated in Table 3. The pH of the system is adjusted to 5.0 using sodium acetate buffer (Aldrich). After the pH adjustment, 0.5 gm of the enzymes solution is added. All the hydrolysis reaction were run for 72 hrs and various samples were analyzed for sugars using the HPLC method described below at different time points.

Analytical Methods

Solids compositional analysis of the feedstock, the pre-digested and the digested biomass samples were conducted using standard TAPPI T 222 and T 249 methods. Component of feedstock (Example 9) and digested biomass samples (Example 10-12) are shown in Table 2.

The concentration of sugars (glucose, xylose) after enzymatic hydrolysis was quantified by high-performance liquid chromatography (HPLC) system (Shimadzu) equipped with a refractive index detector (Shimadzu) on a BIO-RAD 87H Column. Prior to injection, the samples were filtered through 0.45 μm HV filters (Millipore, Bedford, Mass., USA), and a volume of 10 μL was injected. The mobile phase for the column was 5 mM H2SO4 in Milli-Q water at a flow rate of 0.6 mL/min.

Yield was calculated as weight percentage ratio of oven dried digested biomass material to the total amount of feed (on dry basis).

Table 1 indicates the pre-digestion and digestion runs carried out under various operating conditions. All the pre-digestion experiments are carried out in the presence of formic acid as organic acid, while the digestion experiments are carried out in the presence of sodium hydroxide as alkali. All the experiments were carried out with wood to liqour (W:L ratio) ratio as indicated in the Table 1. Examples 1-4 were carried out in 500 ml zipperclave, while examples 5-8 were carried in Parr5000 unit. Example 2 represents substrate that undergoes a pre-digestion and a subsequent digestion treatment (essentially 2-step process), while Example 1 and 3 undergo only pre-digestion and digestion step respectively (single step). Wood chip feedstocks and various pre-digested and digested biomass were analyzed for overall carbohydrates and lignin content as indicated in the Table 2.

TABLE 1 Pre-digestion and Digestion Experiments Al- Residence Acid kali Sub- W:L Temp time (wt (wt # Reaction strate Ratio [C.] (min) %) %) Yield 1 Pre- Wood 1:4 160 150 1 78.2 digestion chips 2 Digestion Ex. 1 1:4 160 120 3 79.2 3 Digestion Wood 1:4 160 150 3 78.3 chips 4 Pre- Wood 1:10 150 150 1 72.5 digestion chips 5 Digestion Ex. 4 1:10 80 150 1 80 6 Digestion Ex. 4 1:10 80 150 3 75.3 7 Digestion Ex. 4 1:10 150 150 1 60 8 Digestion Ex. 4 1:10 150 150 3 48.6

TABLE 2 Biomass Compositional Analysis Carbohydrates Ex # Sample Lignin Glucan Xylan Total 9 Wood 26.9 45 18 63 10 Ex. 1 32.5 59.5 5.5 65 11 Ex. 2 31.0 62.9 1.3 64.2 12 Ex. 3 23.4 53.4 15.3 68.7

All the samples prepared indicated in Table 1 were hydrolyzed at 2 wt % glucan consistency using cellulases for 72 hrs. Overall hydrolysis for glucan and xylan are reported in Table 3 for substrate prepared as per examples 1-3.

TABLE 3 Enzymatic Hydrolysis Experiments % Glucan % Xylan Hydrolysis Solids Released Released Example Content on glucan (based on (based on # Substrate basis (wt %) pulp) pulp) 13 Ex. 1 2 56 65 14 Ex. 2 2 81 100 15 Ex. 3 2 70 69

Using the data gathered on the yield for each pre-digestion and digestion step in Table 1 and the glucan and xylan recovery during hydrolysis as indicated in Table 2, overall carbohydrate recovery values are calculated for examples 1-3 as indicated in Table 4. The values presented in Table 4 indicate monomers carbohydrates recovered (on original wood content) during the pre-digestion step and after pulp hydrolysis. The rest are either lost in the digestion step or unconverted after hydrolysis. It can be easily seen that 2-step (pre-digestion followed by digestion, example 2) has much higher yield than doing each step individually followed by the enzymatic hydrolysis (example 1 and 3). The results clearly indicate that combination of 2-step can have significant yield advantages (from 6-15%) which can further improve the economic viability of the process. The data presented in Table 3 does suggest that the 2-step process indeed makes the pulp more amenable to enzymatic hydrolysis. Also, this process scheme has the advantage of a separate hemicelluloses extracted stream that can be converted to fuels or chemicals via different process technology such as furanic fuels.

TABLE 4 Calculations for overall carbohydrate recovery in pre-digestion and after enzymatic hydrolysis (wt % based on original wood) Overall car- Exam- Com- Pre- Pulp bohydrate ple Substrate ponents Feed digestion Hydrolysis Recovery 16 Ex. 1 Glucan 45 0 26.0 26.0 68 Xylan 18 13.7 2.8 16.5 Total 63 13.7 28.8 42.6 17 Ex. 2 Glucan 45 0 31 31 73 Xylan 18 13.7 0.8 14.5 Total 63 13.7 31.8 46.1 18 Ex. 3 Glucan 45 — 29.3 29.3 60 Xylan 18 — 8.2 8.2 Total 63 — 37.5 37.5

While 2-step process clearly has yield advantages, each step can further be optimized with other parameters such as temperature and alkali concentration as indicated in Table 1, Example 5-8. The fermentable glucose released is indicated in Table 5 and FIG. 4 which allows for further reduction in the operating cost and improves process efficiency.

TABLE 5 Glucose concentration (g/L) after enzymatic hydrolysis at 2 wt % glucan consistency on substrates prepared by various operating parameters for digestion step Time (h) Example Substrate 0 1 2 4 24 48 72 19 Ex. 5 0.0 3.2 4.3 6.3 14.3 17.1 18.2 20 Ex. 6 0.0 3.2 4.6 6.6 14.9 17.9 19.1 21 Ex. 7 0.0 4.5 6.2 8.4 16.9 19.1 20.2 22 Ex. 8 0.0 8.1 10.7 13.4 21.8 23.8 24.7 

What is claimed is:
 1. A process for producing alcohol is provided comprising: (a) providing a biomass containing celluloses, hemicelluloses and lignin; (b) contacting said biomass at a temperature within the range from about 130° C. to about 230° C. with an aqueous solution comprising a dilute acid with concentration of up to 10 wt % in an aqueous solution to biomass ratio in the range of 2 to 10 thereby producing a predigested stream comprising an aqueous liquor comprising at least a portion of hemicelluloses and a residual biomass comprising celluloses and lignin; (c) separating at least a portion of the aqueous liquor from the residual biomass thereby providing an aqueous liquor stream and a pre-digested biomass stream; (d) contacting said pre-digested biomass stream with a cooking liquor comprising (i) about 0.5 to about 20 wt %, based on the cooking liquor, of at least one alkali selected from the group consisting of sodium hydroxide, sodium carbonate, sodium sulfide, potassium hydroxide, potassium carbonate, ammonium hydroxide, and mixtures thereof and (ii) water, at a cooking liquor to biomass ratio within the range of 2 to 6, at a temperature within the range of 60° C. to 230° C. to provide a digested biomass stream containing digested biomass containing cellulosic material, hemicellulosic material, and lignin, and a chemical liquor stream containing at least one sodium compound, potassium compound, or ammonium compound; (e) washing the digested biomass stream with a water stream thereby removing at least a portion of lignin and hemicellulosic material and producing washed digested biomass stream; (f) hydrolyzing the washed digested biomass stream by treating the streams with an enzyme solution comprising cellulases and optionally xylanases at a pH within the range of about 3 to about 7 at a temperature within the range of 30° C. to 90° C. to produce a hydrolyzate containing from about 4% to 30% by weight of fermentable sugar; (g) fermenting the hydrolyzate in the presence of a microorganism at a temperature with the range of about 25° C. to about 55° C. at a pH within the range of about 4 to about 6 thereby producing an alcohol stream containing at least one alcohol having 2 to 18 carbon atoms; and (h) recovering at least one of said alcohol from the alcohol stream and producing an aqueous effluent stream.
 2. The process of claim 1 further comprising providing at least a portion of the aqueous liquor stream to the hydrolyzate prior to fermenting in step (g).
 3. The process of claim 2 further comprising subjecting the washed digested biomass stream to oxygen delignification and mechanically refining solids in the washed digested biomass stream prior to contacting the washed digested biomass stream with cellulases in step (f), thereby reducing the solids in size.
 4. The process of claim 2 wherein in step (e) the water stream is flowing countercurrent to the digested biomass steam.
 5. The process of claim 1 further comprising providing at least a portion of the aqueous liquor stream to the washed digested biomass stream prior to hydrolyzing in step (f).
 6. The process of claim 1 wherein 0.1 to 3%, based on the cooking liquor, of anthraquinone, sodium borate and/or polysulfides is present in the cooking liquor of (d).
 7. The process of claim 1 further comprising concentrating the washed digested biomass stream from step (e) by mechanical dewatering prior to contacting the washed digested biomass stream with cellulases in step (f) thereby increasing the solids content of the washed digested biomass stream from 15 to 40 wt % solids.
 8. The process of claim 7 further comprising subjecting the thus-concentrated washed digested biomass stream to oxygen delignification prior to contacting the washed digested biomass stream with cellulases in step (f).
 9. The process of claim 7 further comprising subjecting the thus-concentrated washed digested biomass stream to mechanically refining solids in the washed digested biomass stream prior to contacting the washed digested biomass stream with cellulases in step (f), thereby reducing the solids in size.
 10. The process of claim 7 further comprising subjecting the thus-concentrated washed digested biomass stream to oxygen delignification and mechanically refining solids in the washed digested biomass stream prior to contacting the washed digested biomass stream with cellulases in step (f), thereby reducing the solids in size.
 11. The process of claim 1 further comprising subjecting the washed digested biomass stream to oxygen delignification prior to contacting the washed digested biomass stream with cellulases in step (f).
 12. The process of claim 1 further comprising mechanically refining solids in the washed digested biomass stream prior to contacting the washed digested biomass stream with cellulases in step (f), thereby reducing the solids in size.
 13. The process of claim 1 further comprising (i) removing at least a portion of the lignin from one of washed digested biomass stream, hydrolyzate, or alcohol stream prior to step (d) or (e) thereby providing a washed digested biomass stream, hydrolyzate, or alcohol stream containing less than 5% lignin content based on said stream.
 14. The process of claim 1 further comprising, (j) concentrating the chemical liquor stream from step (d) to produce a concentrated chemical liquor stream, (k) burning said concentrated chemical liquor stream to produce a chemical recycle stream, (1) recausticizing said chemical recycle stream to produce a cooking liquor feed stream, and (m) recycling the cooking feed stream to the digester in step (d) as at least a portion of the cooking liquor.
 15. The process of claim 14 further comprising (n) removing at least a portion of the lignin from the aqueous effluent stream to produce an aqueous effluent recycle stream which is recycled through the chemical recycle stream.
 16. The process of claim 1 where the cooking liquor has a pH from 8 to 14 and a temperature in the range of 100° C. to 230° C.
 17. The process of claim 1 wherein the cooking liquor comprises 0.5 to 20 wt %, based on the cooking liquor, of sodium hydroxide.
 18. The process of claim 1 wherein the cooking liquor has a sulfidity in the range from about 15% to about 40%.
 19. The process of claim 1 wherein the active alkali is in the range of 10 to 20%.
 20. The process of claim 1 wherein the cooking liquor to biomass ratio is in the range of 3 to
 5. 